Apparatus and method for manufacturing insulated wall panels

ABSTRACT

The present invention relates to an apparatus and method for manufacturing unitary insulated wall panels, wherein the panels form a cavity for receiving expandable foam insulation, and form integral attachment means for attaching the panel to a building wall system. Unitary foam insulated panels having integral attachment means are further provided.

CROSS-REFERENCES

This application claims the priority benefit as a divisional applicationof U.S. patent application Ser. No. 13/995,836 filed on Jun. 19, 2013,which claims the benefit under 35 U.S.C. §371 as the U.S. national stageentry of International Application No. PCT/CA2012/000585 filed Jun. 15,2012, which claims the priority benefit under 35 U.S.C. §119(e) of U.S.Provisional Patent Application No. 61/498,414 filed Jun. 17, 2011 and ofU.S. Provisional Patent Application No. 61/511,447 filed Jul. 25, 2011,the disclosures of which are incorporated herein by reference in theirentireties.

TECHNICAL FIELD

An apparatus and method for manufacturing insulated wall panels isprovided. More specifically, an apparatus and method for manufacturingspray or pour foam insulated panel, such as external wall panels andcurtain wall panels is provided.

BACKGROUND

Prefabricated insulated exterior wall panels are designed to spanmultiple floors of a building, and are being constructed to withstandthermal changes (e.g. temperature-related expansion and contraction),moisture and condensation buildup, wind and other forces, while at thesame time keeping air and water from penetrating the building envelopeand contributing to a decorative appearance. Due to new Leadership inEnergy and Environmental Design (“LEED”) standards, current insulatedpanels, such as curtain wall “backpanels” or external aluminum compositepanels (ACPs), are necessarily being constructed to provide thermalefficiency (i.e. high heat transfer coefficient) for cost-effectiveheating, cooling and lighting in a building, while contributing to adecorative and aesthetically pleasing exterior appearance.

Aluminum Composite Panels (ACPs) are commonly used as external wallpanels in building construction for external cladding (buildingfacades), for insulation and/or for signage. Existing ACPs typicallycomprise a non-aluminum internal core bonded with one aluminum sheet, orsandwiched between two sheets, depending upon the type and style ofpanel. For instance, ACPs may comprise two external aluminum sheets, or“skins”, that are adhered together by an internal insulating core. Wheretwo sheets are utilized, a thermal plastic core such as, for example, apolyethylene (PE) or other polymer foam material (e.g. expandedpolyurethane or expanded resin) may be used. Various forms of ACPs areknown including, without limitation, Reynobond® panels, Alucobond®panels and Alpolic® panels.

Curtain walls can comprise a non-structural exterior covering of abuilding, and are typically constructed with extruded aluminum or steelmembers. The metal frame of the curtain wall is typically non-loadbearing and can house glass or other opaque decorative coverings thatare used in combination with internal, insulated “backpanels”, known as“curtain wall panels”.

Although not apparent from the exterior of the building, the backpanelsin a curtain wall system often comprise considerable insulation. Thebackpanels are not only designed to withstand thermal changes, moistureand condensation, wind and other forces, while at the same time keepingair and water from penetrating the building envelope, but they are alsodesigned to maintain pressure and temperature consistency in theintentional gap formed between the backpanel and the decorative opaquecovering.

Unlike ACPs, insulated curtain wall backpanels may comprise formedsheet(s) of steel or aluminum and a cavity or “back-section” filled withinsulation. Traditionally, insulated backpanels may comprise rigidfiberglass or mineral wool insulation fastened inside a cavity formedfrom a single sheet of aluminum or steel. Alternatively, one form ofinsulated composite panel comprises two external aluminum or steelsheets having expanded insulating material sandwiched therebetween. Forinstance, as described in U.S. Pat. No. 3,530,029, composite panels maybe formed by aligning equal lengths of sheet material, disposing apreformed insulating material therebetween and compressing the threelayers in a press to form a length of panel. The insulating material maya polymer foam material (e.g. expanded polyurethane or other expandedresin) arranged between the two skins.

One common form of rigid wool insulation in traditional backpanels isRoxul CurtainRock®, which is a semi-rigid stone wool insulation board.Where rigid insulation is used, the aluminum or steel sheets are shapedto conform to sizes and shapes in compliance with the desired buildingdesign and then coated with a sealant to create a water and air barrier.Each formed cavity is then prepared to receive and secure expandable orrigid insulation. For example, “stickpins” can be installed to extendfrom the interior surface of the panel and are then coated with adhesiveand used to hold the insulation in position.

The success of this insulation process depends upon the skill of theworker to adequately coat the pan and stickpins with the sealant and/oradhesive and then to pre-cut the insulation to the size of the backpan(i.e. to minimize gaps between the insulation and the backpan). Problemsarise where the sealant is misapplied, resulting in air and waterentering the backpan and causing the buildup of condensation. Further,thermal “shorts” or weaknesses often result where the insulation has notbeen installed properly and where it must part to allow the stickpins topuncture through the fibrous material. As a result, fluctuations in airpressure cause airflow through the gaps which can cause “whistling”noises. Heat buildup behind the insulation can also cause “drumming”noises due to vibration of the metal skin of the backpan andcondensation buildup in the space between the insulation and the metalskin. Semi-rigid insulation can sag and weaken over time, causing thenecessity for costly maintenance or repair. Finally, offcut insulationcannot be reused and creates waste.

Existing insulated ACPs and curtain wall panels also require additionalattachment means such as, non-integrated extruded aluminum fasteners forinstalling the insulated panel to the building wall. The requiredattachment means complicates the installation process and requires thatthe panels conform to precise size and shape specifications. The complexpanel attachment methods and the current types of insulation furtherrestrict the ability to adapt or change the size and shape of theinsulated panels on site, as may be required where building orarchitectural designs changes.

There exists a need for an efficient system of manufacturing insulatedexterior wall panels and curtain wall backpans, each made from one pieceof aluminum or steel and an effective and efficient form of insulation,thereby eliminating the need for both traditional curtain wall backpanelelements and complicated composite panel construction. There is furthera need for a system of manufacturing insulated wall panels havingintegral attachment means. There is a need for a system capable ofmanufacturing lighter external wall panels and backpanels which are madeof one piece of metal and insulated with a spray- or pour-foaminsulation. The system may be entirely automated.

SUMMARY

An apparatus for manufacturing unitary insulated wall panels isprovided, the apparatus comprising bending means capable of bending orforming a panel from a sheet of metal. The panel is formed to have acavity comprising at least one sidewall and a bottom wall for receivingand containing the insulation, and attachment means, integral to the atleast one sidewall, for affixing the panel to a wall. The apparatusfurther comprises insulation application means for applying expandablefoam insulation to the cavity.

A method of manufacturing a unitary insulated wall panel is furtherprovided, the method comprising the steps of (1) bending a sheet ofmetal to form a panel having an enclosed cavity capable of receiving andcontaining foam insulation, and integral attachment means for attachingthe panel to a wall system and (2) applying expandable foam insulationto the cavity.

A unitary insulated wall panel forming an enclosed cavity capable ofreceiving and containing foam insulation and having integral attachmentmeans extending from the panel for attaching the panel to a wall system,wherein the insulation comprises expandable foam insulation is furtherprovided.

BRIEF DESCRIPTION OF THE FIGURES

FIG. 1 shows perspective view of the present apparatus,

FIG. 2a shows a front (external) perspective view of a wall panel (e.g.a Strataclad™ internal square lock panel),

FIG. 2b shows a rear (internal) view of the wall panel depicted in 2 a,

FIG. 2c shows a front plan view of the wall panel depicted in 2 a,

FIG. 2d shows a cross-sectional view of the panel in FIG. 2c taken alonglines “A-A” without insulation,

FIG. 2e shows a cross-sectional view of the panel in FIG. 2c taken alonglines “A-A” with insulation,

FIG. 3a shows a front (external) perspective view of a wall panel (e.g.a Strataclad™ vertical locking panel),

FIG. 3b shows a rear (internal) view of the wall panel depicted in 3 a,

FIG. 3c shows a front plan view of the wall panel depicted in 3 a,

FIG. 3d shows a cross-sectional view of the panel in FIG. 3c taken alonglines “A-A” without insulation,

FIG. 3e shows a cross-sectional view of the panel in FIG. 3c taken alonglines “A-A” with insulation,

FIG. 4a shows a front (external) perspective view of a wall panel (e.g.a Strataclad™ bevelled vertical locking panel),

FIG. 4b shows a rear (internal) view of the wall panel depicted in 4 a,

FIG. 4c shows a front plan view of the wall panel depicted in 4 a,

FIG. 4d shows a cross-sectional view of the panel in FIG. 4c taken alonglines “A-A” without insulation,

FIG. 4e shows a cross-sectional view of the panel in FIG. 4c taken alonglines “A-A” with insulation,

FIG. 5a shows a rear (internal) perspective view of a curtain wallbackpanel (e.g. an Envatherm™ box-style backpan),

FIG. 5b shows a plan view of the backpan depicted in 5 a,

FIG. 5c shows a cross-sectional view of the backpan depicted in 5 btaken along the lines “A-A” without insulation,

FIG. 5d shows a cross-sectional view of the backpan depicted in 5 btaken along the lines “A-A” with insulation,

FIG. 6a shows a rear (internal) perspective view of a curtain wallbackpanel (e.g. an Envatherm™ inner flange backpan),

FIG. 6b shows a plan view of the backpan depicted in 6 a,

FIG. 6c shows a cross-sectional view of the backpan depicted in 6 btaken along the lines “A-A” without insulation,

FIG. 6d shows a cross-sectional view of the backpan depicted in 6 btaken along the lines “A-A” with insulation,

FIG. 7a shows a rear (internal) perspective view of a curtain wallbackpanel (e.g. an Envatherm™ square flange backpan),

FIG. 7b shows a plan view of the backpan depicted in 7 a,

FIG. 7c shows a cross-sectional view of the backpan depicted in 7 btaken along the lines “A-A” without insulation,

FIG. 7d shows a cross-sectional view of the backpan depicted in 7 btaken along the lines “A-A” with insulation,

FIG. 8a shows a perspective view of the insulation applicator applyingthe foam insulation to a panel,

FIG. 8b shows a front view of the insulation applicator, and

FIG. 8c shows a side view of the insulation applicator.

DESCRIPTION OF EMBODIMENTS

A method and apparatus is provided for manufacturing an insulatedexternal wall panel and curtain wall backpanel formed from a unitary(i.e. non-sandwiched) piece of metal, wherein the panel forms a cavityfor receiving non-rigid, expandable pour- or spray-foam insulation, andintegral attachment means for positioning the panel on the wall and/orin conjunction with adjacent panels and fastening elements, as required.A pour- or spray-foam insulated external wall panel and curtain wallbackpanel, as manufactured by the present method or apparatus, is alsoprovided.

Having regard to FIG. 1, the present apparatus 100 comprises providing ameans of forming or bending a single sheet of metal, such as aluminum orsteel, into a unitary panel. In one embodiment, the “bender” 10 may beautomated and may be capable of receiving flat sheets of metal 5 andforming them into bent panels 15 having a variety of shapes, sizes anddimensions (FIGS. 2-7). Each bent panel 15 forms an interior cavity 16,having at least one sidewall 17 and a bottom wall 18, for receiving andcontaining the foam insulation, whereby the cavity is enclosed andcapable of retaining the insulation. For example, where the panel issquare or rectangular in shape, the cavity may comprise four sidewalls17 and a bottom wall 18. It is contemplated that the panel bendingprocess may be manual or partially manual, for example, where panels arecustom made.

Each panel 15 also forms integral attachment means, comprising at leastone flange 35 of various shapes and sizes extending from the panel 15.For example, the at least one lateral flange 35 may extend from one orall of the at least one sidewall(s) 17. In one embodiment, theattachment means may be used in accordance with a pre-existing fasteningassembly to house the panel, such as in a curtain wall system. Inanother embodiment, the attachment means may not only be utilized toaffix the panel directly to the wall, such as in an external wall panelsystem, but may also be utilized as an interlocking means to affix thepanel to adjacent panels (or other exterior components, such as windows)on the wall. For instance, the integral attachment means are designed toconnect the panel to corresponding attachment means on the wall system,on adjacent panels and other structures, or both.

Having regard to FIGS. 2-7, square or rectangular panels 15 may vary insize from, for example, a minimum dimension of approximately 14″×14″ toa maximum dimension of approximately 52″×96″. The panels may also varyin depth having, for example, a maximum depth of 6″ and a minimum depthof 1½″. Varied depth and tapered panels may provide a decorativeexterior to a building wall system where some panels may rest flushagainst the surface of the building, while others protrude outwardly. Itis understood that the present bent panels 15 may be any size, shape ordimension as may be architecturally or structurally required.

The present apparatus 100 may further comprise clinching means (notshown), such as a Norlok Surelok III, for creating a clinchlok joint ateach corner of the bent panel 15. The clinchlok joint may be formed byany means capable of squeezing and securing the sides of the bent panel15. For example, the clinchlok may be formed by a rounded punch and diecapable of creating a “mushroom” seal, thereby eliminating or reducingthe need to penetrate the panel walls with rivets or other sealingmeans.

The present apparatus 100 may further comprise heating means 20, such asan oven, for heating the panel 15. Such heating means 20 may be utilizedto optimize adhesion of the pour- or spray-foam to the at least onesidewall(s) 17 of the panel 15 upon application of the insulation.Optimizing adherence of the insulation foam to the at least onesidewall(s) 17 of the cavity 16 can prevent the foam insulation frompeeling away from the at least one sidewall(s) 17 and collapsinginwardly, thereby providing sufficient insulation density and reducingthe amount of foam required to fill the cavity 16. In one embodiment,the oven 20 may be used to heat the bent panels 15 to betweenapproximately 80-100° F. In a preferred embodiment, the oven 20 may beutilized to heat the bent panels 15 to approximately 95° F.

Having regard to FIGS. 8a-8c , the present apparatus 100 furthercomprises insulation application means 30 for applying the pour- orspray-foam insulation into the enclosed cavity 16 of the bent panel 15.It is contemplated that the insulation applicator 30 may be manuallyoperated or automated, and, where automated, may be in communicationwith, and programmed to receive, the bent panel 15 from the bender 10.

Having regard to FIGS. 8a-8c , the insulation applicator 30 may comprisean applicator head 31 having a nozzle 32 for spraying or pouring thefoam insulation into the cavity 16. Where automated, the insulationapplicator 30 may be programmed to manoeuvre the nozzle 32 above thecavity 16. In order to optimize the insulation process, a pre-determinedamount of foam may be dispensed at a pre-determined rate and pressure ina pre-determined pattern. The amount of foam and rate of application mayvary depending upon the size, shape and depth of the panel. The processmay optimized to ensure that the panels are not overfilled, therebyreducing the use of an excess volume of foam and providing sufficientair (density) within insulation.

In one embodiment, the applicator head 31 may further be designed to mixsome or all of the foam insulation material prior to applying the foamto the cavity 16. In another embodiment, some or all of the foammaterial may be pre-mixed.

In one embodiment, a panel 15 having at least one sidewall 17 with a 4inch depth may receive approximately 37-39 cc of foam insulation persecond, dispensed at a rate of 750 lineal inches per minute. A panelhaving at least one sidewall with a 1½ inch depth may receiveapproximately 22 cc of insulation at a speed of 800 lineal inches perminute. Having regard to FIG. 8a , application of the foam may commenceat a position inset from the at least one sidewall(s) 17 of the cavity16, thereby providing sufficient space for the insulation to expand. Theinset position may further prevent use of excess insulation and preventthe insulation from spilling over the edge of the at least onesidewall(s) 17 and into the panel attachment means 35 (e.g. see FIG. 5d). Preferably, the insulation may be applied in a particular pattern(e.g. horizontal zig-zagging lines along the bottom wall 18, see FIG. 8a) to optimize coverage of the entire cavity 16. The distance between thezig-zagging lines may also be determined to further optimize the amountof insulation used.

The pour- or spray-foam insulation may be expandable foam insulationmaterial (e.g. plastic material), wherein the material is capable ofadhering to a metal panel and creating a seal therewith. The foam mayexpand rapidly, for example, at a ratio of 60:1. The foam insulation mayfurther comprise a flame-retardant material (e.g. does not sustain flameupon removal of heat source), and will not melt or drip.

In one embodiment, the foam insulation may comprise polyurethane foaminsulation. In another embodiment, the foam insulation may comprise apolyurethane open-cell spray foam insulation, wherein the insulation iscapable of providing some water and air-permeability. Preferably, thefoam insulation comprises the commercially available Icynene® open-cellspray foam insulation, having a 0.5 lb density free rise. It iscontemplated that closed-cell foam insulation, low (water blown) ormedium density (having blowing agents) foam insulation may be used. Itis further contemplated that the foam may be pre-mixed, or mixedimmediately prior to application to the panel (i.e. mixing means formingpart of the insulation applicator 30).

The foam insulation may be efficiently applied or injected through theinsulation applicator 30 (e.g. spray nozzle 32) into the cavity 16 ofthe bent panel 15, and may provide for accurate and rapid insulation ofthe bent panel 15. For example, each panel 15 may be insulated inapproximately one minute.

Upon application, the foam insulation may solidify or “cure” to anear-solid state, thereby providing increased “racking strength” to theinsulated panel 25 and reducing the need for additional strengtheningmeans (e.g. such as the structural supports commonly required largerpanels or the use of a thicker metal skin). The density and expansivenature of the foam may provide a reduction of thermal shorts and airflow/capture behind the insulation compared to traditional fibreglass ormineral wool insulation, thereby reducing “drumming” noise andpotentially eliminating gaps in the seal causing “whistling” noises. Thefoam insulation may provide a lighter panel than those which incorporatetraditional insulation methods or composite (sandwich) panels, andprovide a means of insulating a panel without the use of stickpins.

In one embodiment, the present insulated panel 25 may be lighter thanexisting fiberglass or mineral wool insulated panels. Lighter panels canbe manufactured in larger sizes and positioned higher on buildingstructures. Further, due to the design of the panel 15, and the enclosedinterior cavity 16, two insulated panels 25 can be joined togetheron-site, thereby effectively doubling the size of the insulated panel 25positioned on the wall, while still providing a completely insulatedsystem. The ability to accurately control the amount of foam applied toeach panel 15 can reduce or nearly eliminate wasted foam.

It is contemplated that any expandable pour- or spray-foam materialcapable of filling, adhering to, and insulating an enclosed (or multiplesided), open faced cavity of a wall panel, having appropriate densityand insulative characteristics, may be used. It is further contemplatedthat such insulation material should not be subject to loss ofinsulation ability (i.e. R value) over time, and should be capable ofwithstanding wind and gravitational forces, settling effects,moisture-related conditions, convection and air filtration. It isfurther contemplated that such foam insulation should not react with, orbe impacted by, any sealants (such as Tremco Commercial Sealants)applied to the panel, or any affixing means, during installation.

The present apparatus 100 may optionally further comprise providingpressing means 40, capable of receiving the foam-insulated panels 25 andfor containing the panels until the foam has cured or “solidified” (e.g.reaches a near-solid state). In one embodiment, the press 40 may beutilized to prevent overflow of foam outside of the panel, and toprovide a smooth flat finish to the insulation (i.e. to stop theinsulation from continuing to expand above the at least one sidewall(s)17 of the cavity 16). The pressing means 40 or “press” may be adjustableto account for the size, shape and dimensions of the panels, includingmulti-sided panels. The press may be manually operated or automated and,where automated, be in communication with both the bender 10 and theinsulation applicator 30 to provide an entirely automated andpre-programmable system. It is further contemplated that passage orconveyance of the panels through the present apparatus 100 may beentirely automated.

A method of manufacturing foam insulated wall panels is furtherprovided, the method comprising, providing bending means 10 for forminga sheet of metal 5 into a bent panel 15 having an interior cavity 16with at least one sidewall 17 and a bottom wall 18, and applyingexpandable pour- or spray-foam insulation to the cavity 16. The presentmethod may optionally further comprise pressing the insulated panel 25to contain the expanding foam insulation within the cavity 16 until thefoam solidifies or cures.

In one embodiment, the present method may further comprise applying anair-permeable sheet or foil material to the insulated panel 25 beforethe panel 25 enters the press 40. The sheet or foil material may extendacross the enclosed cavity 16, thereby covering the cavity 16. The sheetor foil may be a permeable material capable of maintaining air andmoisture flow through to the insulation, while protecting the insulationfrom UV light or other contaminants to which the panel may be exposedduring construction. The sheet or foil may further comprise afire-retardant material. In one embodiment, the sheet or foil maycomprise insulation vapour retarders or foil, which are commerciallyavailable, such as provided by LAMTEC® Corporation (www.lamtec.com).

Pour- or spray foam insulated external wall or curtain wall backpanelsof various shapes and sizes are further provided. Each panel comprises aunitary panel forming an enclosed cavity 16, having at least onesidewall 17 and a bottom wall 18, and integral attachment meansextending from the at least one sidewall(s) 17, for affixing theinsulated panel 25 to a wall system and/or to adjacent insulated panelsor other structures. The present insulated panels 25 may be utilized andinstalled in residential or commercial buildings. For example, havingregard to FIGS. 2-4, the present exterior wall panels may be utilized toprovide raised, revealed decorative paneling where traditional AluminumComposite Panels (ACPs) are utilized. Further, having regard to FIGS.5-7, the present insulated curtain wall backpanels may be installed oncommon curtain wall structures, and may provide considerable insulationbehind spandrel glass or any opaque panel.

The present apparatus 100 and method provide a system of manufacturinginsulated panels 25 having a reduced gauge of steel or aluminum comparedto traditional panels, resulting in a lighter panel that may be largerin size and positioned higher on building sites.

It is contemplated that, where architecturally desired, the presentapparatus 100 and method may be utilized to produce pour- or spray-foaminsulated spandrel-type panels to be used in combination with thepresent insulated curtain wall backpanels 25. The insulated spandrelpanels could be used to further insulate the curtain wall system, andprovide further control over temperature and moisture fluctuations withthe wall (e.g. in the gap between the spandrel panel and the curtainwall backpan).

Although a few preferred embodiments have been shown and described, itwill be appreciated by those skilled in the art that various changes andmodifications might be made without departing from the scope of theinvention. The terms and expressions in the preceding specification havebeen used therein as terms of description and not of limitation, andthere is no intention in the use of such terms and expressions ofexcluding equivalents of the features shown and described or portionsthereof, it being recognized as the scope of the invention as definedand limited only by the claims that follow.

What is claimed is:
 1. A method of manufacturing a unitary insulated wall panel, the method comprising: (a) providing a bender for bending a single sheet of metal to form a panel having an enclosed and open-faced cavity comprising four sidewalls and a bottom wall for receiving and containing insulation, the four sidewalls defining four sides around a perimeter of the open-faced cavity of the panel, and at least one panel attachment element, the attachment element comprising at least one lateral flange extending from and integral to at least one of the sidewalls; (b) providing a foam applicator for applying expandable foam insulation to the open-faced cavity, wherein the foam is applied using an applicator head configured to dispense the foam insulation at a pre-determined rate and pressure, in a pre-determined pattern, and to provide a pre-determined amount of air within the foam insulation, and (c) providing a press for pressing the panel while the foam cures, the press means configured to prevent overflow of foam outside of the panel and to provide a flat finish to an insulation surface.
 2. The method of claim 1, further comprising providing a heater for heating the panel prior to applying the expandable foam insulation.
 3. The method of claim 2, wherein the panel is heated to a temperature of approximately 80-100° F.
 4. The method of claim 3, wherein the panel is heated to a temperature of 95° F.
 5. The method of claim 1, further providing applying an air-permeable foil to the panel after applying the expandable foam insulation.
 6. The method of claim 1, wherein the foam insulation is polyurethane foam insulation.
 7. The method of claim 6, wherein the polyurethane foam insulation is an open-cell spray foam insulation.
 8. The method of claim 1, wherein the panels are manufactured of steel or aluminum.
 9. The method of claim 1, wherein the panels are exterior wall panels or curtain wall backpanels.
 10. The method of claim 1, wherein some or all of the method is automated.
 11. A method of manufacturing a unitary insulated wall panel, the method comprising: (a) providing a bender for bending a single sheet of metal to form a panel having an enclosed and open-faced cavity comprising four sidewalls and a bottom wall for receiving and containing insulation, the four sidewalls defining four sides around a perimeter of the open-faced cavity of the panel, and at least one panel attachment element, the attachment element comprising at least one lateral flange extending from and integral to at least one of the sidewalls; (b) providing an oven for heating the open-faced panel, and (c) providing a foam applicator for applying expandable foam insulation to the open-faced cavity, wherein the foam is applied using an applicator head configured to dispense the foam insulation at a pre-determined rate and pressure, in a pre-determined pattern, and to provide a pre-determined amount of air within the foam insulation.
 12. The method of claim 11, wherein the panel is heated to a temperature of approximately 80-100° F.
 13. The method of claim 12, wherein the panel is heated to a temperature of 95° F.
 14. The method of claim 11, wherein the method further comprises providing a press for pressing the panel while the foam cures, the press means configured to prevent overflow of foam outside of the panel and to provide a flat finish to an insulation surface.
 15. The method of claim 14, further providing applying an air-permeable foil to the panel after pressing the expandable foam insulation.
 16. The method of claim 11, wherein the foam insulation is polyurethane foam insulation.
 17. The method of claim 16, wherein the polyurethane foam insulation is an open-cell spray foam insulation.
 18. The method of claim 11, wherein the panels are manufactured of steel or aluminum.
 19. The method of claim 11, wherein the panels are exterior wall panels or curtain wall backpanels.
 20. The method of claim 11, wherein some or all of the method is automated.
 21. A unitary insulated wall panel bent from a single sheet of metal to form an enclosed and open-faced cavity comprising four sidewalls and a bottom wall for receiving and containing expandable foam insulation, the four sidewalls defining four sides around a perimeter of the open-faced cavity of the panel, and at least one lateral flange extending from and integral to at least one of the sidewalls for attaching the panel to a wall.
 22. The panel of claim 21, wherein the foam insulation is polyurethane foam insulation.
 23. The panel of claim 22, wherein the polyurethane foam insulation is an open-cell spray foam insulation.
 24. The panel of claim 21, wherein the panels are manufactured of steel or aluminum.
 25. The panel of claim 21, wherein the panels are exterior wall panels or curtain wall backpanels. 